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Formation of solar cells with conductive barrier layers and foil substratesRelated Patent Categories: Batteries: Thermoelectric And Photoelectric, Photoelectric, CellsFormation of solar cells with conductive barrier layers and foil substrates description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070000537, Formation of solar cells with conductive barrier layers and foil substrates. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a continuation-in-part of commonly assigned, co-pending U.S. patent application Ser. No. 10/943,685, entitled "Formation of CIGS Absorber Layers on Foil Substrates", filed Sep. 18, 2004. This application is also a continuation-in-part of commonly assigned, co-pending U.S. patent application Ser. No. 11/039,053, entitled "Series Interconnected Optoelectronic Device Module Assembly", filed Jan. 20, 2005 and a continuation-in-part of commonly assigned, co-pending U.S. patent application Ser. No. 11/039,053, entitled "Optoelectronic Architecture Having Compound Conducting Substrate", filed Aug. 16, 2005. This application is related to commonly assigned, co-pending U.S. patent application Ser. No. 10/771,250 entitled "Photovoltaic Devices Fabricated from Insulating Template with Conductive Coating" and filed on Feb. 2, 2004. The entire disclosures of the above applications are fully incorporated herein by reference for all purposes. FIELD OF THE INVENTION [0002] The present invention relates to photovoltaic devices and more specifically to fabrication of absorber layers for photovoltaic devices. BACKGROUND OF THE INVENTION [0003] Efficient photovoltaic devices, such as solar cells, have been fabricated using absorber layers made with alloys containing elements of group IB, IIIA and VIA, e.g., alloys of copper with indium and/or gallium or aluminum and selenium and/or sulfur. One common combination of the aforementioned elements is copper-indium-gallium-diselenide (CIGS) and the resulting devices are often referred to as CIGS solar cells. The CIGS absorber layer may be deposited on a substrate. It would be desirable to fabricate such an absorber layer on an aluminum foil substrate because aluminum foil is relatively inexpensive, lightweight, and flexible. Unfortunately, current techniques for depositing CIGS absorber layers are incompatible with the use of aluminum foil as a substrate. [0004] Typical deposition techniques include evaporation, sputtering, chemical vapor deposition, and the like. These deposition processes are typically carried out at high temperatures and for extended times. Both factors can result in damage to the substrate upon which deposition is occurring. Such damage can arise directly from changes in the substrate material upon exposure to heat, and/or from undesirable chemical reactions driven by the heat of the deposition process. Thus, very robust substrate materials are typically required for fabrication of CIGS solar cells. These limitations have excluded the use of aluminum and aluminum-foil based foils. [0005] An alternative deposition approach is the solution-based printing of the CIGS precursor materials onto a substrate. Examples of solution-based printing techniques are described, e.g., in Published PCT Application WO 2002/084708 and commonly-assigned U.S. patent application Ser. No. 10/782,017, both of which are incorporated herein by reference. Advantages to this deposition approach include both the relatively lower deposition temperature and the rapidity of the deposition process. Both advantages serve to minimize the potential for heat-induced damage of the substrate on which the deposit is being formed. [0006] Although solution deposition is a relatively low temperature step in fabrication of CIGS solar cells, it is not the only step. In addition to the deposition, a key step in the fabrication of CIGS solar cells is the selenization and annealing of the CIGS absorber layer. Selenization introduces selenium into the bulk CIG or CI absorber layer, where the element incorporates into the film, while the annealing provides the absorber layer with the proper crystalline structure. In the prior art, selenization and annealing has been performed by heating the substrate in the presence of H.sub.2Se or Se vapor and keeping this nascent absorber layer at high temperatures for long periods of time. [0007] While use of Al as a substrate for solar cell devices would be desirable due to both the low cost and lightweight nature of such a substrate, conventional techniques that effectively anneal the CIGS absorber layer also heat the substrate to high temperatures, resulting in damage to Al substrates. There are several factors that result in Al substrate degradation upon extended exposure to heat and/or selenium-containing compounds for extended times. First, upon extended heating, the discrete layers within a Mo-coated Al substrate can fuse and form an intermetallic back contact for the device, which decreases the intended electronic functionality of the Mo-layer. Second, the interfacial morphology of the Mo layer is altered during heating, which can negatively affect subsequent CIGS grain growth through changes in the nucleation patterns that arise on the Mo layer surface. Third, upon extended heating, Al can migrate into the CIGS absorber layer, disrupting the function of the semiconductor. Fourth, the impurities that are typically present in the Al foil (e.g. Si, Fe, Mn, Ti, Zn, and V) can travel along with mobile Al that diffuses into the solar cell upon extended heating, which can disrupt both the electronic and optoelectronic function of the cell. Fifth, when Se is exposed to Al for relatively long times and at relatively high temperatures, aluminum selenide can form, which is unstable. In moist air the aluminum selenide can react with water vapor to form aluminum oxide and hydrogen selenide. Hydrogen selenide is a highly toxic gas, whose free formation can pose a safety hazard. For all these reasons, high-temperature deposition, annealing, and selenization are therefore impractical for substrates made of aluminum or aluminum alloys. [0008] Because of the high-temperature, long-duration deposition and annealing steps, CIGS solar cells cannot be effectively fabricated on aluminum substrates (e.g. flexible foils comprised of Al and/or Al-based alloys) and instead must be fabricated on heavier substrates made of more robust (and more expensive) materials, such as stainless steel, titanium, or molybdenum foils, glass substrates, or metal- or metal-oxide coated glass. Thus, even though CIGS solar cells based on aluminum foils would be more lightweight, flexible, and inexpensive than stainless steel, titanium, or molybdenum foils, glass substrates, or metal- or metal-oxide coated glass substrates, current practice does not permit aluminum foil to be used as a substrate. [0009] Thus, there is a need in the art for a method for fabricating solar cells on aluminum substrates. SUMMARY OF THE INVENTION [0010] Embodiments of the present invention address at least some of the drawbacks set forth above. The present invention provides photovoltaic devices that are cost-effectively manufactured in high-throughput manner on foil substrates. The thin, flexible nature of the photovoltaic devices may also allow them to be rolled or folded into a smaller form factor for ease of transportation but also allow for streamlined fabrication. Embodiments of the present invention may also be designed to reduce the amount raw materials used in the manufacturing process. It also should be understood that embodiments of the present invention may be adapted for use with absorber layers of a variety of materials and are not limited to only CIGS absorber layers. At least some of these and other objectives described herein will be met by various embodiments of the present invention. [0011] In one embodiment of the present invention, a method of manufacturing photovoltaic devices may be comprised of providing a substrate having at least one electrically conductive metal foil substrate, at least one electrically conductive diffusion barrier layer, and at least one electrically conductive electrode layer above the diffusion barrier layer. Although not limited to the following, the foil substrate may be an aluminum foil substrate. The electrically conductive diffusion barrier layer may prevent chemical interaction between the aluminum foil substrate and the electrode layer. The method may include forming an absorber layer on the substrate. In one embodiment, the absorber layer may be a non-silicon absorber layer. In another embodiment, the absorber layer may be an amorphous silicon (doped or undoped) absorber layer. Optionally, the absorber layer may be based on organic and/or inorganic materials. [0012] For any of the embodiments described herein, the following may also apply. The forming step may be comprised of first forming a nascent absorber layer. The nascent absorber layer may be reacted to form a dense film. In some embodiments, the dense film is the absorber layer. In other embodiments, the dense film is process in another step to form the desired absorber layer. The nascent absorber layer may be heated to form a dense film. It should be understood that the diffusion barrier layer inhibits inter-diffusion of aluminum in the foil substrate and metal in the electrode layer during heating. The diffusion barrier layer may include one or more of the following materials: chromium, vanadium, tungsten, glass, and/or nitrides, tantalum nitride, tungsten nitride, titanium nitride, zirconium nitride, hafnium nitride, and silicon nitride, oxides, or carbides. The electrode layer may be comprised of molybdenum. Alternatively, the electrode layer may be comprised of copper, silver, aluminum, and niobium. [0013] In another embodiment of the present invention, a photovoltaic device is provided having a substrate comprising of at least one electrically conductive aluminum foil substrate, at least one electrically conductive diffusion barrier layer, and at least one electrically conductive electrode layer above the diffusion barrier layer, wherein the diffusion barrier layer prevents chemical interaction between the aluminum foil substrate and the electrode layer. The device may include an absorber layer formed on the substrate. In one embodiment, the absorber layer may be a non-silicon absorber layer. Optionally, the absorber layer may be based on organic and/or inorganic materials. [0014] In yet another embodiment of the present invention, a method for forming an absorber layer of a photovoltaic device comprises providing a substrate having at least one electrically conductive metallized polymer foil substrate, at least one electrically conductive diffusion barrier layer, and at least one electrically conductive back electrode layer above the diffusion barrier layer. The diffusion barrier layer prevents chemical interaction between the metallized polymer foil substrate and the back electrode layer. The method may include forming an absorber layer on the substrate. In one embodiment, the absorber layer may be a non-silicon absorber layer. In another embodiment, the absorber layer may be an amorphous silicon (doped or undoped) absorber layer. Optionally, the absorber layer may be based on organic and/or inorganic materials. The foil substrate may contain a polymer selected from the group of: polyesters, polyethylene naphtalates, polyetherimides, polyethersulfones, polyetheretherketones, polyimides, and/or combinations of the above. The metal used for metallization of the polymer foil substrate may be aluminum or an alloy of aluminum with one or more metals. [0015] In a still further embodiment of the present invention, a photovoltaic device is provided comprising of a substrate having at least one electrically conductive aluminum foil substrate, at least one electrically conductive diffusion barrier layer, and at least one electrically conductive back electrode layer above the diffusion barrier layer, wherein the diffusion barrier layer prevents chemical interaction between the aluminum foil substrate and the back electrode layer. The device may include an absorber layer formed on the substrate. In one embodiment, the absorber layer may be a non-silicon absorber layer. In another embodiment, the absorber layer may be an amorphous silicon (doped or undoped) absorber layer. Optionally, the absorber layer may be based on inorganic and/or organic materials. [0016] For any of the embodiments described herein, the following may also apply. The absorber layer may include one or more inorganic materials selected from the following: titania (TiO2), nanocrystalline TiO2, zinc oxide (ZnO), copper oxide (CuO or Cu2O or CuxOy), zirconium oxide, lanthanum oxide, niobium oxide, tin oxide, indium oxide, indium tin oxide (ITO), vanadium oxide, molybdenum oxide, tungsten oxide, strontium oxide, calcium/titanium oxide and other oxides, sodium titanate, potassium niobate, cadmium selenide (CdSe), cadmium suflide (CdS), copper sulfide (Cu2S), cadmium telluride (CdTe), cadmium-tellurium selenide (CdTeSe), copper-indium selenide (CuInSe2), cadmium oxide (CdOx), CuI, CuSCN, a semiconductive material, a group IB element, a group IIIA element, a group VIA element, or any combination of the above. [0017] Optionally, any of the photovoltaic devices disclosed in the present application may include an organic material in the absorber layer. The absorber layer may include one or more organic materials from the following: a conjugated polymer, poly(phenylene) and derivatives thereof, poly(phenylene vinylene) and derivatives thereof (e.g., poly(2-methoxy-5-(2-ethyl-hexyloxy)-1,4-phenylene vinylene (MEH-PPV), poly(para-phenylene vinylene), (PPV)), PPV copolymers, poly(thiophene) and derivatives thereof (e.g., poly(3-octylthiophene-2,5,-diyl), regioregular, poly(3-octylthiophene-2,5,-diyl), regiorandom, Poly(3-hexylthiophene-2,5-diyl), regioregular, poly(3-hexylthiophene-2,5-diyl), regiorandom), poly(thienylenevinylene) and derivatives thereof, and poly(isothianaphthene) and derivatives thereof, 2,2'7,7'tetrakis(N,N-di-p-methoxyphenyl-amine)-9,9'-spirobifluor- ene(spiro-Me OTAD), organometallic polymers, polymers containing perylene units, poly(squaraines) and their derivatives, and discotic liquid crystals, organic pigments or dyes, ruthenium-based dye, liquid iodide/triiodide electrolyte, azo-dyes having azo chromofores (--N.dbd.N--) linking aromatic groups, phthalocyanines including metal-free phthalocyanine; (HPc), perylenes, perylene derivatives, Copper pthalocyanines (CuPc), Zinc Pthalocyanines (ZnPc), naphthalocyanines, squaraines, merocyanines and their respective derivatives, poly(silanes), poly(germinates), 2,9-Di(pent-3-yl)-anthra[2,1,9-def:6,5,10-d'e'f'] diisoquinoline-1,3,8,10-tetrone, and 2,9-Bis-(1-hexyl-hept-1-yl)-anthra[2,1,9-def:6,5,10-d'e'f']diisoquinoline- -1,3,8,10-tetrone and pentacene, pentacene derivatives and/or pentacene precursors, an N-type ladder polymer such as poly(benzimidazobenzophenanthroline ladder) (BBL), or any combination of the above. [0018] For any of the embodiments described herein, the following may also apply. The absorber layer may include one or more materials from the group consisting of: an oligimeric material, micro-crystalline silicon, inorganic nanorods dispersed in an organic matrix, inorganic tetrapods dispersed in an organic matrix, quantum dot materials, ionic conducting polymer gels, sol-gel nanocomposites containing an ionic liquid, ionic conductors, low molecular weight organic hole conductors, C60 and/or other small molecules, or combinations of the above. The absorber layer may be comprised of one or more of the following: a nanostructured layer having an inorganic porous template with pores filled by an organic material (doped or undoped), a polymer/blend cell architecture, a micro-crystalline silicon cell architecture, or combinations of the above. [0019] Optionally, a photovoltaic device module may use any of the photovoltaic devices disclosed in the present application in a high efficiency cell configuration described below. The photovoltaic device module may include the photovoltaic device, an insulator layer, and a conductive back plane, wherein the insulator layer is sandwiched between the substrate and the back plane. A transparent conducting layer may be disposed such that the absorber layer is between the substrate and the transparent conducting layer. One or more electrical contacts may be positioned between the transparent conducting layer and the back plane to define a conductive pathway, wherein the electrical contacts are formed through the transparent conducting layer, the absorber layer, the substrate, and the insulating layer. The electrical contacts may be electrically isolated from the absorber layer, the substrate, and the insulating layer. The coupling of the electrical contacts to the back plane allows the back plane to carry electric current. Since the back plane carries electric current from one device module to the next, the pattern of traces on the top side of the device need not contain thick busses, as used in the prior art for this purpose. Instead, the pattern of traces need only provide sufficiently conductive "fingers" to carry current to the electrical contacts. In the absence of busses, a greater portion of the absorber layer is exposed, which enhances efficiency. In addition, a pattern of traces without busses can be more aesthetically pleasing. [0020] A further understanding of the nature and advantages of the invention will become apparent by reference to the remaining portions of the specification and drawings. Continue reading about Formation of solar cells with conductive barrier layers and foil substrates... 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